Pages 1 to 8 of the Service Bulletin Pages 1 to 10 of the Service Bulletin Revised 3. Accomplishment Instructions to introduce a best cleaning process and inspection. Renumbered existing Appendix 4 to Appenidx 5 and added pictures of acceptable and unacceptable process cleaned discs to Appendix 4. Revised Appendix A. Updated 1.B. Reason, 1.D. Compliance, 1.E. Approval, 1.F. Manpower, 1.G. Tooling and 1.I. References. Revised Figure in Appendix 3 to add a note. Minor non-technical changes also made. All pages of Appendix 1 Page 1 and 2 of Appendix 1 Revised 3. Accomplishment Instructions to introduce a best cleaning process and inspection. Renumbered existing Appendix 4 to Appenidx 5 and added pictures of acceptable and unacceptable process cleaned discs to Appendix 4. Revised Appendix A. Updated 1.B. Reason, 1.D. Compliance, 1.E. Approval, 1.F. Manpower, 1.G. Tooling and 1.I. References. Revised Figure in Appendix 3 to add a note. Minor non-technical changes also made. All pages of Appendix 2 Pages 1 to 10 of Appendix 2 Revised 3. Accomplishment Instructions to introduce a best cleaning process and inspection. Renumbered existing Appendix 4 to Appenidx 5 and added pictures of acceptable and unacceptable process cleaned discs to Appendix 4. Revised Appendix A. Updated 1.B. Reason, 1.D. Compliance, 1.E. Approval, 1.F. Manpower, 1.G. Tooling and 1.I. References. Revised Figure in Appendix 3 to add a note. Minor non-technical changes also made.**Printed in Great Britain**



# RB.211−72−AG493 Transmittal - Page 2All pages of Appendix 3 Page 1 and 2 of Appendix 3 Revised 3. Accomplishment Instructions to introduce a best cleaning process and inspection. Renumbered existing Appendix 4 to Appenidx 5 and added pictures of acceptable and unacceptable process cleaned discs to Appendix 4. Revised Appendix A. Updated 1.B. Reason, 1.D. Compliance, 1.E. Approval, 1.F. Manpower, 1.G. Tooling and 1.I. References. Revised Figure in Appendix 3 to add a note. Minor non-technical changes also made. All pages of Appendix 4 Pages 1 to 17 of Appendix 4 Revised 3. Accomplishment Instructions to introduce a best cleaning process and inspection. Renumbered existing Appendix 4 to Appenidx 5 and added pictures of acceptable and unacceptable process cleaned discs to Appendix 4. Revised Appendix A. Updated 1.B. Reason, 1.D. Compliance, 1.E. Approval, 1.F. Manpower, 1.G. Tooling and 1.I. References. Revised Figure in Appendix 3 to add a note. Minor non-technical changes also made. Pages 1 to 6 of Appendix 5 Revised 3. Accomplishment Instructions to introduce a best cleaning process and inspection. Renumbered existing Appendix 4 to Appenidx 5 and added pictures of acceptable and unacceptable process cleaned discs to Appendix 4. Revised Appendix A. Updated 1.B. Reason, 1.D. Compliance, 1.E. Approval, 1.F. Manpower, 1.G. Tooling and 1.I. References. Revised Figure in Appendix 3 to add a note. Minor non-technical changes also made.**Printed in Great Britain**



# RB.211−72−AG493 Transmittal - Page 3LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin following incorporation of Revision 2 are as follows: Page Revision NumberRevision Date

Bulletin R 1 2 Oct.12/12 R 2 2 Oct.12/12 R 3 2 Oct.12/12 R 4 2 Oct.12/12 R 5 2 Oct.12/12 R 6 2 Oct.12/12 R 7 2 Oct.12/12 R 8 2 Oct.12/12 R 9 2 Oct.12/12 R 10 2 Oct.12/12 Appendix 1 R 1 2 Oct.12/12 R 2 2 Oct.12/12 Appendix 2 R 1 2 Oct.12/12 R 2 2 Oct.12/12 R 3 2 Oct.12/12 R 4 2 Oct.12/12 R 5 2 Oct.12/12 R 6 2 Oct.12/12 R 7 2 Oct.12/12 R 8 2 Oct.12/12 R 9 2 Oct.12/12 R 10 2 Oct.12/12 Appendix 3 R 1 2 Oct.12/12 R 2 2 Oct.12/12 Appendix 4 R 1 2 Oct.12/12 R 2 2 Oct.12/12 R 3 2 Oct.12/12 R 4 2 Oct.12/12 R 5 2 Oct.12/12 R 6 2 Oct.12/12 R 7 2 Oct.12/12 R 8 2 Oct.12/12 R 9 2 Oct.12/12 R 10 2 Oct.12/12 R 11 2 Oct.12/12 R 12 2 Oct.12/12**Printed in Great Britain**



# RB.211−72−AG493 Transmittal - Page 4R 13 2 Oct.12/12 R 14 2 Oct.12/12 R 15 2 Oct.12/12 R 16 2 Oct.12/12 R 17 2 Oct.12/12 Appendix 5 R 1 2 Oct.12/12 R 2 2 Oct.12/12 R 3 2 Oct.12/12 R 4 2 Oct.12/12 R 5 2 Oct.12/12 R 6 2 Oct.12/12**Printed in Great Britain**



# RB.211−72−AG493 Transmittal - Page 51. Planning Information A. Effectivity (1) Boeing 747 RB211-524G2-19, 524G2-19/11, 524G2-19/15, 524G2-T-19, 524G2-T-19/11, 524G2-T-19/15 Engines with IP turbine disc serial numbers listed in Appendix 1. RB211-524G3-19, 524G3-19/15, 524G3-T-19, 524G3-T-19/15 Engines with IP turbine disc serial numbers listed in Appendix 1. RB211-524H2-19, 524H2-19/11, 524H2-19/15, 524H2-T-19, 524H2-T-19/11, 524H2-T-19/15 Engines with IP turbine disc serial numbers listed in Appendix 1. (2) Boeing 757 RB211-535E4-37, 535E4-37/10, 535E4-37/11, 535E4-37/12, 535E4-37/14, 535E4-37/16, 535E4-37/17, 535E4-37/19, 535E4-37/20, 535E4-37/23, 535E4-37/24, 535E4-37/25, 535E4-37/39, 535E4-37/43, 535E4-37/44 Engines with IP turbine disc serial numbers listed in Appendix 2 RB211-535E4-B-37/15, 535E4-B-37/19, 535E4-B-37/20, 535E4-B-37/21, 535E4-B-37/25, 535E4-B-37/35, 535E4-B-37/39, 535E4-B-37/41, 535E4-B-37/44 Engines with IP turbine disc serial numbers listed in Appendix 2 RB211-535E4-C-37, 535E4-C-37/43 Engines with IP turbine disc serial numbers listed in Appendix 2 (3) Boeing 767 RB211-524H-36, 524H-36/11, 524H-T-36, 524H-T-36/11 Engines with IP turbine disc serial numbers listed in Appendix 1. (4) Tupolev Tu204 RB211-535E4-B-75, 535E4-B-75/25 Engines with IP turbine disc serial numbers listed in Appendix 2. ENGINE - IP TURBINE DISC - REMOVAL DUE TO STEEL INCLUSION CONCERNS - NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AG493**Printed in Great Britain**



# RB.211−72−AG493 Page 1 of 10 Oct. 8/10 Oct.12/12 RB. Reason The inspection of 3-off IP Turbine discs at engine overhaul, in the period 1998-2001, identified the presence of a steel inclusion. IP turbine discs are manufactured from forgings of Waspaloy (Nickel) material. Following the discovery of the steel inclusions an investigation was launched in 1999, this identified several other discs with steel contamination. The investigation concluded that all the contaminated discs were manufactured from billets produced pre 1997 at a supplier who also melted steel in the same furnaces. In 1997 procedures were changed to introduce dedicated furnaces for Waspaloy production. An analysis of the effect of the steel inclusions on the disc life concluded that the lives would be unaffected. This analysis has recently been repeated utilising the improved stress models now available, it is now concluded that the Declared Safe Cyclic Life (DSCL) cannot be supported for some discs with an inclusion. Four forgings are generally produced from a billet of Waspaloy material. The Waspaloy material was generally melted in campaigns using several consecutive melts of Waspaloy. Analysis of the melt data for the discs containing inclusions has concluded that the Waspaloy melts produced immediately after a steel melt have the highest risk of containing an inclusion. Material from the same source was utilised to manufacture RB211-524G, 524H and 535E4 discs.
Non-Modification Service Bulletin (NMSB) 72-AG418 was raised to remove three discs from service, from batches known to have been contaminated; the discs from NMSB72-AG418 are also included in this NMSB. Revision 1 introduces an inspection of IP turbine discs to allow discs withdrawn in accordance with the initial issue of this NMSB to be returned to service. Revision 2 introduces a number of changes: R (1) A best practice cleaning process and inspection standard to make sure that discs are cleaned to a sufficient level to allow the SQUID inspection to be completed. R R R (2) A best practice packaging process to reduce the risk of contamination after the disc has been cleaned. R R (3) A note that this NMSB is subject to an Airworthiness Directive. R (4) A correction to a part number, typographical error in Table 1. R (5) Changes to reflect issue 2 of QCTP BRR0144 in Appendix 4. R (6) A clarification in 1.D. Compliance section. R**Printed in Great Britain**



# RB.211−72−AG493 Page 2 Oct. 8/10 Oct.12/12 RC. Description This NMSB instructs the removal and inspection of the potentially affected discs. The applicable Part Numbers (EIPC 72-51-31, Fig/Item 01-150) are: (1) RB211-524G and 524H series Engines: LK82335, UL27958, UL37681, UL37721. (2) RB211-524G-T and 524H-T series Engines: UL38383, UL38384, UL38467, UL38929, UL38930. (3) RB211-535E4 series Engines: UL17774, UL19818, UL27940. D. Compliance

ALERT Rolls-Royce recommends that: (1) RB211-535E4 IP turbine discs as listed in Appendix 2 are to be removed from service prior to reaching the maximum life (cycles) as defined in the Appendix.
NOTE: The maximum life (cycles) for all the RB211-524G/H discs listed in Appendix 1 is the declared safe cyclic life as defined in the Time Limits Manual. (2) IP turbine discs exposed at a shop visit (Engine level 3 or 4 shop visit or 05 module level 2 shop visit), with a cyclic life greater than the inspection threshold as defined in Appendix 1 or 2. These IP turbine discs must be inspected in accordance with 3. Accomplishment Instructions prior to further use.
NOTE: Refer to example shown in Appendix 3. (3) Discs exposed at a shop visit (Engine level 3 or 4 or 05 module level 2) after the initial issue date of this NMSB, R should be inspected but may continue in service without inspection provided: (a) The cyclic life at that shop visit exposure is less than the inspection threshold as defined in Appendix 1 or 2.**Printed in Great Britain**



# RB.211−72−AG493 Page 3 Oct. 8/10 Oct.12/12 R(b) The disc is planned to be removed for inspection prior to the inspection threshold as defined in Appendix 1 or 2.
NOTE: Installed engines fitted with IP turbine discs at lives above the inspection threshold, at the date of issue of this NMSB, may continue in service until next shop visit or until reaching the maximum life (cycles) whichever occurs first.
NOTE: Refer to example shown in Appendix 3.
NOTE: Discs listed in Appendix 1 or 2 fitted into engines, that have had an engine level 3 or 4 or 05 module level 2 shop visit, after the initial issue date of this Service Bulletin, must not be operated above the inspection threshold life defined in Appendix 1 or 2. (4) For steps (1), (2) or (3) above, once a disc has been inspected in accordance with 3. Accomplishment Instructions, R R and has passed the inspection, R the disc can be returned to service for the remainder of the declared safe cyclic life as defined by R the applicable Time Limits Manual. E. Approval
The technical content of Non-Modification Service Bulletin 72-AG493 was approved under the authority of EASA Design Organisational Approval No.EASA.21J.035 on Oct. 5/10, Oct.27/11 R and was re-approved on Oct.12/12. The actions contained within this NMSB are the subject of an EASA Airworthiness Directive. It is anticipated that an FAA Airworthiness Directive will follow. R RF. Manpower (1) On-wing: Removal and installation of engine - 48 manhours
(2) At overhaul: (a) IPT disc cleaning R
16 R hours elapsed time
5.5 R man hours (b) SQUID (Superconductive Quantitative Induction Device) inspection
10 man hours
NOTE: The SQUID inspection is R defined in section 3. The Personnel for the SQUID inspection should be qualified and approved to the requirements of the NDE Training Pack TP0044.**Printed in Great Britain**



# RB.211−72−AG493 Page 4 Oct. 8/10 Oct.12/12 RG. Tooling FITMHT01 - IPT Disc Lifting and turnover tool SQUID Equipment - Refer to Appendix 4
H. Consumable Materials
None
I. References (1) Rolls-Royce RB211 Service Bulletin 72-AG418 Engine - IP Turbine Disc - Removal Due To Steel Contamination Concerns - Non-Modification Service Bulletin
(2) Time Limits Manual (TLM) (a) T-211(524)-7RR (RB211-524G/H Engines) (b) T-211(535)-6RR (RB211-535E4-37 Engines) (c) T-211(535)-4RR (RB211-535E4-75 Engines)
(3) Standard Practices Manual
TSD594J Task 72-00-00-300-363
2. Material Information
None**Printed in Great Britain**



# RB.211−72−AG493 Page 5 Oct. 8/10 Oct.12/12 R3. Accomplishment Instructions A. Review Group A parts records to confirm the location of the affected discs

B. Remove the discs from service prior to reaching the limits defined in 1.D. Compliance

C. Inspect the disc for evidence of previous inspection accomplishment - Refer to section 3.H. R

NOTE: The inspection is not required to be repeated
D. Clean and examine the R IPT disc in preparation for the inspection for steel inclusions using SQUID. Clean and examine the disc in accordance with: R (1) Degrease disc in accordance with TSD594J 70-00-00-100-101 or TSD594J 70-00-00-100-102 or TSD594J 70-00-00-100-118. R R (2) Immerse the parts fully in an OMat 173 alkaline deruster to TSD594J Task 70-00-00-100-121, Subtask 70-00-00-110-121-001 for between 25 and 35 minutes. R R R (3) Rinse the parts fully in clean, cold, running water and pressure wash with an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to remove all traces of process solution. R R R (4) Remove Heat Oxidation/Corrosion via an Acid descale, step (1). Immerse the parts fully in the OMat 1/152 or OMat 1/153 (acid descaler) for between 25 and 30 minutes. Refer to TSD594J Task 70-00-00-100-134, Subtask 70-00-00-180-134-002 for the make-up and typical operation parameters for some OMat 1/152 solutions and Subtask 70-00-00-180-134-001 for the make-up and typical operation parameters for some OMat 1/153 solutions. R R R R R R (5) Rinse the parts fully in clean, cold, running water and pressure wash with an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to remove all traces of process solution. R R R (6) Scale condition with OMat 198. Immerse the parts fully in OMat 198 alkaline permanganate for a minimum of 1 hour and maximum of 2 hours. The solution made up as specified in TSD594J Task 70-00-00-100-134 Subtask 70-00-00-180-134-003. R R R R (7) Rinse the parts fully in clean, cold, running water and pressure wash with an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to remove all traces of process solution. R R R**Printed in Great Britain**



# RB.211−72−AG493 Page 6 Oct. 8/10 Oct.12/12 R(8) Remove Heat Oxidation/Corrosion via an Acid descale, step (2). Immerse the parts fully in the OMat 1/152 or OMat 1/153 (acid descaler) for between 25 and 30 minutes. Refer to TSD594J Task 70-00-00-100-134, Subtask 70-00-00-180-134-002 for the make-up and typical operation parameters for some OMat 1/152 solutions and Subtask 70-00-00-180-134-001 for the make-up and typical operation parameters for some OMat 1/153 solutions. R R R R R R (9) Rinse the parts fully in clean, cold, running water and pressure wash with an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to remove all traces of process solution. R R R (10) Repeat steps (6), (7), (8) and (9) (Scale Condition, Rinse, Acid Descale and Rinse). R R (11) Dry the disc by immersing fully in clean, hot water at 80 deg. C minimum. Allow the parts to reach the water temperature. Remove the parts from the hot water and dry fully with a blast of clean, dry, oil free compressed air. R R R R
(12) Plastic media blast the entire disc once in accordance with TSD594J Task 70-00-00-100-104 Subtask 70-00-00-120-104-005. R R
NOTE: Make sure difficult to clean areas such as firtree serrations and the bores of bolt holes are not missed during the plastic media blast operation. R R R
CAUTION: DO NOT DWELL IN ANY AREA FOR TOO LONG. IF YOU DWELL FOR TOO LONG YOU CAN CAUSE UNACCEPTABLE METAL REMOVAL R R (13) Repeat steps (6), (7), (8) and (9) (Scale Condition, Rinse, Acid Descale and Rinse). R R (14) Dry the disc by immersing fully in clean, hot water at 80 deg.C minimum. Allow the parts to reach the water temperature. Remove the parts from the hot water and dry fully with a blast of clean, dry, oil free compressed air. R R R R
(15) Examine the disc to make sure the oxidation and corrosion is removed. Use the pictures in Appendix 5 to assist in making an assessment: R R (a) Examine the whole disc for general cleanliness. The general surface finish should appear shiny with no oxide scale, corrosion or contamination evident. R R R (b) Examine the firtree serrations for excessive oxide scale, corrosion or other contamination. R R (c) Examine the bores of bolt holes and cooling air holes in the front flange/disc drive arm for excessive oxide scale, corrosion or other contamination. R R R**Printed in Great Britain**



# RB.211−72−AG493 Page 7 Oct. 8/10 Oct.12/12 R(d) Examine the web to rim filet radius for excessive oxide scale, corrosion or other contamination. R R (e) Examine the drive arm, disc bore and disc web areas for excessive oxide scale, corrosion or other contamination. R R If excessive oxide, corrosion or contamination remain and the disc is judged not to be clean enough to attempt a SQUID inspection then repeat steps (6), (7), (8) and (9) up to a maximum of 2 further times (5 times in total). If the cleaning process has been repeated to a maximum of 5 times total and the disc is still not judged to be clean enough contact Rolls-Royce for further advice. If the disc is judged to be clean enough go to step (16) below. R R R R R R R
NOTE: For oxidation or corrosion that is difficult to remove, the immersion time in the OMat 198 alkaline permanganate can be increased to 16 hours maximum. R R R
NOTE: For oxidation or corrosion that is difficult to remove, ultrasonic agitation can be used to assist the cleaning process. Refer to TSD594J Task 70-00-00-100-134 Subtask 70-00-00-270-134-001. R R R R
NOTE: The SQUID inspection is highly sensitive to any remaining ferro-magnetic contamination (including oxide scale). Failure to clean the disc to the required standard will lead to delays in the SQUID inspection process and may require the disc to be returned for further process cleaning. If doubts exist on whether the disc has achieved the required cleanliness standard, photos of the applicable areas can be sent to Rolls-Royce Deutschland for further advice. The contact address is CoTES@Rolls-Royce.com. R R R R R R R R R
NOTE: The multiple number of Scale Conditioning and Acid Descale cycles defined in the procedure above has been determined based on the anticipated life consumed of the disc and a trial to confirm cleaning best practice. R R R R (16) Degrease in accordance with TSD594J 70-00-00-100-102 or TSD594J 70-00-00-100-118 R R
NOTE: Rinse thoroughly, preferably with demineralised water to prevent staining. R R
NOTE: Handle whilst wearing clean cotton gloves after cleaning. RE. Package the disk for transportation: R (1) Make sure transportation box is cleaned before use and free from any debris. R R**Printed in Great Britain**



# RB.211−72−AG493 Page 8 Oct. 8/10 Oct.12/12 R(2) Cover the bottom of the box with a clean polythene sheet (or equivalent). R
NOTE: Do not use anti-corrosion VCI paper to inhibit the disc. This can contaminate the disc by leaving a greasy residue. R R (3) Place disc in box, using clean cotton gloves, and secure to prevent movement during transportation. R R
NOTE: Make sure the disc is not contaminated when being secured within the box. R R (4) Cover disc with a clean polythene sheet (or equivalent). R (5) Make sure transportation box is sealed at the earliest opportunity to reduce risk of contamination. R R
F. Send the disc to: RRolls-Royce Deutschland Ltd & Co KG RMaterials Laboratory - FAO SQUID Logistics Co-ordinator (ET-M1) REschenweg 11 R
15827 Blankenfelde-Mahlow RBrandenburg RGermany R
NOTE: It is recommended that Rolls-Royce Deutschland are advised in advance that an inspection will be required, this will minimise the turnaround time. The contact address is CoTES@Rolls-Royce.com. R R RG. Inspect the disc in accordance with the SQUID procedure defined in Appendix 4. If necessary (due to the sensitivity of the inspection equipment to contamination) the component can be cleaned locally at the inspection facility using a cloth (OMat 2/101) and Acetone (OMat 150). R R R R

H. Record of accomplishment (1) Discs that have successfully completed the inspection should be marked with NMSB 72-AG493 as detailed in Fig.1.
NOTE: The marking of the disc will not be completed by Roll-Royce Deutschland. The receiving overhaul shop will need to review the results provided by Rolls-Royce Deutschland and mark the disc as appropriate. R R R R**Printed in Great Britain**



# RB.211−72−AG493 Page 9 Oct. 8/10 Oct.12/12 RLocation for Identity Markings Fig.1**Printed in Great Britain**



# RB.211−72−AG493 Page 10 Oct. 8/10 Oct.12/12 RRB211-524G, 524G-T, 524H, 524H-T Engines - IP Turbine Discs

Disc Serial No.Inspection Threshold (Cycles) Disc Serial No.Inspection Threshold (Cycles)
ADQDY 131 16500 ADQDY 859 16500 ADQDY 236 16500 ADQDY 860 16500 ADQDY 360 16250 ADQDY 869 16500 ADQDY 363 16500 ADQDY 872 16500 ADQDY 378 16500 ADQDY 885 16500 ADQDY 513 16250 ADQDY 887 16500 ADQDY 533 16250 ADQDY 1087 16500 ADQDY 544 16250 ADQDY 1096 16500 ADQDY 551 16500 ADQDY 1097 16500 ADQDY 555 16500 ADQDY 1098 16500 ADQDY 560 16250 ADQDY 1099 16500 ADQDY 565 16500 ADQDY 1111 16500 ADQDY 690 16500 ADQDY 1112 16500 ADQDY 691 16500 ADQDY 1113 16500 ADQDY 698 16500 ADQDY 1130 16500 ADQDY 699 16500 ADQDY 1144 16500 ADQDY 700 16500 ADQDY 1145 16500 ADQDY 701 16500 ADQDY 1146 16500 ADQDY 717 16500 ADQDY 1147 16500 ADQDY 724 16500 ADQDY 1148 16500 ADQDY 725 16500 ADQDY 1177 16500 ADQDY 726 16500 ADQDY 1178 16500 ADQDY 727 16500 ADQDY 1179 16500 ADQDY 728 16500 ADQDY 1180 16500 ADQDY 729 16500 ADQDY 1181 16500 ADQDY 733 16500 ADQDY 1182 16500 ADQDY 734 16500 ADQDY 1183 16500 ADQDY 738 16500 ADQDY 1184 16500 ADQDY 739 16500 ADQDY 1212 16500 ADQDY 760 16500 ADQDY 1213 16500 ADQDY 761 16500 ADQDY 1217 16250 ADQDY 779 16500 ADQDY 1218 16250 ADQDY 780 16500 ADQDY 1220 16250 ADQDY 781 16500 ADQDY 1225 16250 ADQDY 782 16500 ADQDY 1226 16250 ADQDY 799 16500 ADQDY 1227 16250 ADQDY 800 16500 ADQDY 1228 16250 ADQDY 801 16500 ADQDY 1229 16500 ADQDY 802 16500 ADQDY 1230 16500 ADQDY 834 16500 ADQDY 1231 16500 ADQDY 835 16500 ADQDY 1232 16500 ADQDY 836 16500 ADQDY 1254 16250 ADQDY 837 16500 ADQDY 1255 16250 APPENDIX 1**Printed in Great Britain**



# RB.211−72−AG493 Appendix 1 - Page 1 of 2 Oct. 8/10 Oct.12/12 RRB211-524G, 524G-T, 524H, 524H-T Engines - IP Turbine Discs - continued
Disc Serial No.Inspection Threshold (Cycles) Disc Serial No.Inspection Threshold (Cycles)
ADQDY 1268 16500 ADREB 33 16250 ADQDY 1270 16500 ADREB 34 16250 ADQDY 1274 16500 ADREB 36 16250 ADQDY 1502 16500 ADREB 54 16250 ADQDY 1503 16500 ADREB 55 16250 ADQDY 1504 16500 ADREB 56 16250 ADQDY 1520 16250 ADREB 57 16250 ADQDY 1521 16250 ADREB 58 16500 ADQDY 1522 16250 ADREB 71 14000 ADQDY 1523 16250
- -**Printed in Great Britain**



# RB.211−72−AG493 Appendix 1 - Page 2 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs

Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 209 19500 Refer to TLM ADQDY 210 19500 Refer to TLM ADQDY 211 19500 Refer to TLM ADQDY 212 19500 Refer to TLM ADQDY 213 19500 Refer to TLM ADQDY 215 19500 Refer to TLM ADQDY 216 19500 Refer to TLM ADQDY 217 19500 Refer to TLM ADQDY 218 19500 Refer to TLM ADQDY 219 19500 Refer to TLM ADQDY 220 19500 Refer to TLM ADQDY 222 19500 Refer to TLM ADQDY 223 19500 Refer to TLM ADQDY 224 19500 Refer to TLM ADQDY 225 19500 Refer to TLM ADQDY 226 19500 Refer to TLM ADQDY 227 19500 Refer to TLM ADQDY 229 19500 Refer to TLM ADQDY 230 19500 Refer to TLM ADQDY 231 19500 Refer to TLM ADQDY 232 19500 Refer to TLM ADQDY 233 19500 Refer to TLM ADQDY 234 19500 Refer to TLM ADQDY 235 19500 Refer to TLM ADQDY 238 19500 Refer to TLM ADQDY 239 19500 Refer to TLM ADQDY 240 19500 Refer to TLM ADQDY 241 19500 Refer to TLM ADQDY 242 19500 Refer to TLM ADQDY 244 19500 Refer to TLM ADQDY 245 19500 Refer to TLM ADQDY 246 19500 Refer to TLM ADQDY 247 19500 Refer to TLM ADQDY 248 19500 Refer to TLM ADQDY 249 19500 Refer to TLM ADQDY 251 19500 Refer to TLM ADQDY 252 19500 Refer to TLM ADQDY 253 19500 Refer to TLM ADQDY 254 19500 Refer to TLM ADQDY 255 19500 Refer to TLM ADQDY 256 19500 Refer to TLM ADQDY 258 19500 Refer to TLM ADQDY 259 19500 Refer to TLM APPENDIX 2**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 1 of 10 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 260 19500 Refer to TLM ADQDY 261 19500 Refer to TLM ADQDY 262 19500 Refer to TLM ADQDY 263 19500 Refer to TLM ADQDY 264 19500 Refer to TLM ADQDY 265 19500 Refer to TLM ADQDY 266 19500 Refer to TLM ADQDY 267 19500 Refer to TLM ADQDY 269 19500 Refer to TLM ADQDY 270 19500 Refer to TLM ADQDY 271 19500 Refer to TLM ADQDY 272 19500 Refer to TLM ADQDY 273 19500 Refer to TLM ADQDY 274 19500 Refer to TLM ADQDY 275 19500 Refer to TLM ADQDY 276 19500 Refer to TLM ADQDY 277 19500 Refer to TLM ADQDY 279 19500 Refer to TLM ADQDY 282 19500 Refer to TLM ADQDY 283 19500 Refer to TLM ADQDY 284 19500 Refer to TLM ADQDY 285 19500 Refer to TLM ADQDY 286 19500 Refer to TLM ADQDY 287 19500 Refer to TLM ADQDY 288 19500 Refer to TLM ADQDY 289 19500 Refer to TLM ADQDY 290 19500 Refer to TLM ADQDY 291 19500 Refer to TLM ADQDY 292 19500 Refer to TLM ADQDY 293 19500 Refer to TLM ADQDY 294 19500 Refer to TLM ADQDY 295 19500 Refer to TLM ADQDY 296 19500 Refer to TLM ADQDY 297 19500 Refer to TLM ADQDY 298 19500 Refer to TLM ADQDY 299 19500 Refer to TLM ADQDY 301 19500 Refer to TLM ADQDY 302 19500 Refer to TLM ADQDY 303 19500 Refer to TLM ADQDY 304 19500 Refer to TLM ADQDY 305 19500 Refer to TLM ADQDY 308 19500 Refer to TLM ADQDY 309 19500 Refer to TLM ADQDY 311 19500 Refer to TLM ADQDY 312 19500 Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 2 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 313 19500 Refer to TLM ADQDY 314 19500 Refer to TLM ADQDY 315 19500 Refer to TLM ADQDY 401 21500Refer to TLM ADQDY 402 21500Refer to TLM ADQDY 405 19500 Refer to TLM ADQDY 406 19500 Refer to TLM ADQDY 407 19500 Refer to TLM ADQDY 408 19500 Refer to TLM ADQDY 410 19500 Refer to TLM ADQDY 411 19500 Refer to TLM ADQDY 413 21500Refer to TLM ADQDY 416 19500 Refer to TLM ADQDY 417 19500 Refer to TLM ADQDY 418 19500 Refer to TLM ADQDY 419 21500Refer to TLM ADQDY 420 21500Refer to TLM ADQDY 421 21500Refer to TLM ADQDY 422 19500 Refer to TLM ADQDY 423 19500 Refer to TLM ADQDY 424 19500 Refer to TLM ADQDY 425 19500 Refer to TLM ADQDY 426 19500 Refer to TLM ADQDY 427 19500 Refer to TLM ADQDY 429 19500 Refer to TLM ADQDY 430 21500Refer to TLM ADQDY 431 19500 Refer to TLM ADQDY 432 21500Refer to TLM ADQDY 433 21500Refer to TLM ADQDY 435 19500 Refer to TLM ADQDY 436 21500Refer to TLM ADQDY 437 21500Refer to TLM ADQDY 440 19500 Refer to TLM ADQDY 441 19500 Refer to TLM ADQDY 443 21500Refer to TLM ADQDY 444 21500Refer to TLM ADQDY 449 19500 Refer to TLM ADQDY 458 21500Refer to TLM ADQDY 459 21500Refer to TLM ADQDY 460 21500Refer to TLM ADQDY 461 21500Refer to TLM ADQDY 466 21500Refer to TLM ADQDY 474 19500 Refer to TLM ADQDY 475 19500 Refer to TLM ADQDY 486 18500 25500**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 3 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 487 21500Refer to TLM ADQDY 488 21500Refer to TLM ADQDY 489 19500 Refer to TLM ADQDY 592 19500 Refer to TLM ADQDY 593 19500 Refer to TLM ADQDY 594 19500 Refer to TLM ADQDY 595 19500 Refer to TLM ADQDY 596 19500 Refer to TLM ADQDY 597 21500Refer to TLM ADQDY 598 21500Refer to TLM ADQDY 599 21500Refer to TLM ADQDY 618 19500 Refer to TLM ADQDY 620 19500 Refer to TLM ADQDY 621 19500 Refer to TLM ADQDY 626 19500 Refer to TLM ADQDY 627 19500 Refer to TLM ADQDY 628 19500 Refer to TLM ADQDY 629 19500 Refer to TLM ADQDY 634 21500Refer to TLM ADQDY 635 21500Refer to TLM ADQDY 636 21500Refer to TLM ADQDY 637 21500Refer to TLM ADQDY 648 19500 Refer to TLM ADQDY 649 19500 Refer to TLM ADQDY 669 20000 20000 Refer to NMSB72-AG418 ADQDY 671 20000 20000 Refer to NMSB72-AG418 ADQDY 674 21500Refer to TLM ADQDY 675 21500Refer to TLM ADQDY 676 21500Refer to TLM ADQDY 677 21500Refer to TLM ADQDY 893 21500Refer to TLM ADQDY 894 21500Refer to TLM ADQDY 895 21500Refer to TLM ADQDY 896 21500Refer to TLM ADQDY 897 21500Refer to TLM ADQDY 935 19500 Refer to TLM ADQDY 937 19500 Refer to TLM ADQDY 938 19500 Refer to TLM ADQDY 939 21500Refer to TLM ADQDY 940 21500Refer to TLM ADQDY 941 21500Refer to TLM ADQDY 942 21500Refer to TLM ADQDY 955 21500Refer to TLM ADQDY 956 21500Refer to TLM ADQDY 957 21500Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 4 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 981 19500 Refer to TLM ADQDY 982 19500 Refer to TLM ADQDY 983 19500 Refer to TLM ADQDY 984 19500 Refer to TLM ADQDY 997 19500 Refer to TLM ADQDY 998 19500 Refer to TLM ADQDY 999 19500 Refer to TLM ADQDY 1000 19500 Refer to TLM ADQDY 1001 19500 Refer to TLM ADQDY 1002 21500Refer to TLM ADQDY 1003 21500Refer to TLM ADQDY 1004 21500Refer to TLM ADQDY 1005 21500Refer to TLM ADQDY 1010 21500Refer to TLM ADQDY 1011 21500Refer to TLM ADQDY 1012 21500Refer to TLM ADQDY 1013 21500Refer to TLM ADQDY 1014 21500Refer to TLM ADQDY 1022 21500Refer to TLM ADQDY 1023 21500Refer to TLM ADQDY 1024 21500Refer to TLM ADQDY 1025 21500Refer to TLM ADQDY 1026 19500 Refer to TLM ADQDY 1027 19500 Refer to TLM ADQDY 1028 19500 Refer to TLM ADQDY 1029 19500 Refer to TLM ADQDY 1046 21500Refer to TLM ADQDY 1047 21500Refer to TLM ADQDY 1052 18500 25500 ADQDY 1053 18500 25500 ADQDY 1054 18500 25500 ADQDY 1055 18500 25500 ADQDY 1056 18500 26500 ADQDY 1057 18500 25500 ADQDY 1058 18500 25500 ADQDY 1059 18500 26000 ADQDY 1060 18500 25500 ADQDY 1061 18500 25500 ADQDY 1062 19500 Refer to TLM ADQDY 1063 19500 Refer to TLM ADQDY 1064 19500 Refer to TLM ADQDY 1065 19500 Refer to TLM ADQDY 1066 19500 Refer to TLM ADQDY 1067 19500 Refer to TLM ADQDY 1068 19500 Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 5 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 1069 19500 Refer to TLM ADQDY 1070 19500 Refer to TLM ADQDY 1071 21500Refer to TLM ADQDY 1072 21500Refer to TLM ADQDY 1073 21500Refer to TLM ADQDY 1074 21500Refer to TLM ADQDY 1075 19500 Refer to TLM ADQDY 1076 19500 Refer to TLM ADQDY 1077 19500 Refer to TLM ADQDY 1078 19500 Refer to TLM ADQDY 1082 19500 Refer to TLM ADQDY 1085 21500Refer to TLM ADQDY 1086 21500Refer to TLM ADQDY 1287 21500Refer to TLM ADQDY 1288 21500Refer to TLM ADQDY 1289 19500 Refer to TLM ADQDY 1290 19500 Refer to TLM ADQDY 1291 19500 Refer to TLM ADQDY 1292 19500 Refer to TLM ADQDY 1293 21500Refer to TLM ADQDY 1294 21500Refer to TLM ADQDY 1295 21500Refer to TLM ADQDY 1296 21500Refer to TLM ADQDY 1299 18500 25500 ADQDY 1300 19500 Refer to TLM ADQDY 1301 19500 Refer to TLM ADQDY 1302 19500 Refer to TLM ADQDY 1303 19500 Refer to TLM ADQDY 1316 19500 Refer to TLM ADQDY 1317 18500 25500 ADQDY 1319 19500 Refer to TLM ADQDY 1320 19500 Refer to TLM ADQDY 1321 19500 Refer to TLM ADQDY 1322 19500 Refer to TLM ADQDY 1323 19500 Refer to TLM ADQDY 1324 19500 Refer to TLM ADQDY 1325 19500 Refer to TLM ADQDY 1326 18500 25500 ADQDY 1327 18500 25500 ADQDY 1329 18500 25500 ADQDY 1330 18500 26500 ADQDY 1331 18500 25500 ADQDY 1332 18500 25500 ADQDY 1333 18500 25500 ADQDY 1334 21500Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 6 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADQDY 1335 21500Refer to TLM ADQDY 1336 21500Refer to TLM ADQDY 1341 18500 25500 ADQDY 1347 21500Refer to TLM ADQDY 1348 21500Refer to TLM ADQDY 1349 21500Refer to TLM ADQDY 1350 21500Refer to TLM ADQDY 1361 21500Refer to TLM ADQDY 1362 21500Refer to TLM ADQDY 1363 18500 25500 ADQDY 1364 18500 26000 ADQDY 1366 18500 25500 ADQDY 1367 18500 25500 ADQDY 1368 18500 25500 ADQDY 1369 18500 25500 ADQDY 1370 18500 25500 ADQDY 1371 18500 25500 ADQDY 1372 18500 25500 ADQDY 1373 18500 25500 ADQDY 1374 18500 25500 ADQDY 1375 18500 25500 ADQDY 1376 18500 25500 ADQDY 1377 19500 Refer to TLM ADQDY 1378 19500 Refer to TLM ADQDY 1379 19500 Refer to TLM ADQDY 1380 19500 Refer to TLM ADQDY 1381 21500Refer to TLM ADQDY 1382 21500Refer to TLM ADQDY 1383 21500Refer to TLM ADQDY 1384 21500Refer to TLM ADQDY 1385 21500Refer to TLM ADQDY 1386 21500Refer to TLM ADQDY 1387 21500Refer to TLM ADQDY 1388 21500Refer to TLM ADQDY 1389 18500 25500 ADQDY 1390 18500 25500 ADQDY 1391 19500 Refer to TLM ADQDY 1392 19500 Refer to TLM ADQDY 1393 19500 Refer to TLM

- - - ADREB 2 18500 25500 ADREB 4 18500 25500 ADREB 5 18500 26000 ADREB 6 19500 Refer to TLM ADREB 7 19500 Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 7 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADREB 8 19500 Refer to TLM ADREB 9 19500 Refer to TLM ADREB 12 19500 Refer to TLM ADREB 14 19500 Refer to TLM ADREB 15 19500 Refer to TLM ADREB 16 18500 25500 ADREB 17 18500 25500 ADREB 18 18500 25500 ADREB 19 18500 25500 ADREB 35 18500 25500 ADREB 130 21500Refer to TLM ADREB 131 21500Refer to TLM ADREB 135 19500 Refer to TLM ADREB 136 19500 Refer to TLM ADREB 137 19500 Refer to TLM ADREB 139 18500 26000 ADREB 140 18500 25500 ADREB 141 18500 25500 ADREB 142 18500 26000 ADREB 143 19500 Refer to TLM ADREB 144 19500 Refer to TLM ADREB 145 19500 Refer to TLM ADREB 146 19500 Refer to TLM ADREB 153 19500 Refer to TLM ADREB 154 19500 Refer to TLM ADREB 155 19500 Refer to TLM ADREB 156 19500 Refer to TLM ADREB 157 19500 Refer to TLM ADREB 158 19500 Refer to TLM ADREB 159 19500 Refer to TLM ADREB 160 21500Refer to TLM ADREB 161 21500Refer to TLM ADREB 162 21500Refer to TLM ADREB 163 21500Refer to TLM ADREB 164 21500Refer to TLM ADREB 165 21500Refer to TLM ADREB 166 21500Refer to TLM ADREB 167 21500Refer to TLM ADREB 168 19500 Refer to TLM ADREB 169 19500 Refer to TLM ADREB 170 19500 Refer to TLM ADREB 171 19500 Refer to TLM ADREB 172 19500 Refer to TLM ADREB 173 18500 25500 ADREB 174 18500 25500**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 8 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADREB 175 18500 25500 ADREB 176 18500 25500 ADREB 177 18500 25500 ADREB 178 18500 25500 ADREB 179 18500 25500 ADREB 180 21500Refer to TLM ADREB 181 21500Refer to TLM ADREB 182 21500Refer to TLM ADREB 183 21500Refer to TLM ADREB 184 21500Refer to TLM ADREB 185 21500Refer to TLM ADREB 186 20000 20000 Refer to NMSB72-AG418 ADREB 188 18500 25500 ADREB 190 18500 25500 ADREB 191 18500 25500 ADREB 192 18500 25500 ADREB 193 18500 25500 ADREB 194 18500 25500 ADREB 195 18500 25500 ADREB 196 18500 25500 ADREB 197 18500 25500 ADREB 198 18500 25500 ADREB 199 18500 25500 ADREB 200 19500 Refer to TLM ADREB 201 19500 Refer to TLM ADREB 202 19500 Refer to TLM ADREB 203 19500 Refer to TLM ADREB 204 19500 Refer to TLM ADREB 205 19500 Refer to TLM ADREB 206 19500 Refer to TLM ADREB 207 19500 Refer to TLM ADREB 208 19500 Refer to TLM ADREB 209 19500 Refer to TLM ADREB 210 18500 25500 ADREB 211 18500 25500 ADREB 212 18500 25500 ADREB 213 18500 25500 ADREB 214 18500 25500 ADREB 215 18500 25500 ADREB 216 18500 25500 ADREB 217 18500 25500 ADREB 218 18500 25500 ADREB 219 19500 Refer to TLM ADREB 220 19500 Refer to TLM ADREB 221 19500 Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 9 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - IP Turbine Discs - continued
Disc Serial No. Inspection Threshold (Cycles) Maximum Life (Cycles) Remarks

ADREB 222 21500Refer to TLM ADREB 223 21500Refer to TLM ADREB 224 21500Refer to TLM ADREB 225 21500Refer to TLM**Printed in Great Britain**



# RB.211−72−AG493 Appendix 2 - Page 10 Oct. 8/10 Oct.12/12 RRB211-535E4 Engines - High Risk IP Turbine Discs examples

See over APPENDIX 3**Printed in Great Britain**



# RB.211−72−AG493 Appendix 3 - Page 1 of 2 Oct. 8/10 Oct.12/12 RR

Examples of RB211-535E4 high risk IP turbine discs R**Printed in Great Britain**



# RB.211−72−AG493 Appendix 3 - Page 2 Oct. 8/10 Oct.12/12 RSQUID inspection of RB211 IP Turbine Disc QCTP

Part numbers covered by this Document

Engine (RB211) Part Reference Date Makes Detail Number Date Limitations Agreed by Engineering 535E4 UL17774 23.08.10 N/A N/A N/A 535E4 UL19818 23.08.10 N/A N/A N/A 535E4 UL27940 26.04.10 N/A N/A N/A 524G/H LK82335 R 23.08.10 N/A N/A N/A 524G/H UL27958 26.04.10 N/A N/A N/A 524G/H UL37681 23.08.10 N/A N/A N/A 524G/H UL37721 23.08.10 N/A N/A N/A 524G/H-T UL38383 23.08.10 N/A N/A N/A 524G/H-T UL38384 23.08.10 N/A N/A N/A 524G/H-T UL38467 23.08.10 N/A N/A N/A 524G/H-T UL38929 23.08.10 N/A N/A N/A 524G/H-T UL38930 23.08.10 N/A N/A N/A This QCTP covers the SQUID inspection of the RB211-524 and RB211-535 ITP discs The NDT techniques specified herin are mandatory for the components covered in this procedure. No alterations or alternatives to this procedure shall be allowed unless prior to written permission is obtained from the Materials and Technology Dahlewitz

Originator

D.Ruschenbaum Date: 13.02.2012 R NDT Approval

K.Griffiths Date: 21.02.2012

Copyright: This document is the property of Rolls-Royce plc and may not be copied or communicated to a third party or used for any purpose other than that for which it is supplied without the express written authority of Rolls-Royce plc. APPENDIX 4**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 1 of 8 Oct. 8/10 Oct.12/12 RContent Chapter Description Page
1 Scope and Purpose 4

2 Reference Documents 4

3 Definitions and Abbreviations 4

3.1 Definitions 4

3.2 Abbreviations 4

4 Responsibilities 4

4.1 Qualification and approval of SQUID inspection personnel 4

5 Test Procedures 5

5.1 Handling of Turbine Discs 5

5.2 Equipment Requirements 5

5.3 Calibration Reference 6

5.4 Calibration Procedure 7

5.5 Disc Test Procedure 7

5.6 Evaluation Procedure 8**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 2 Oct. 8/10 Oct.12/12 RAppendix A Figures R and Tables 1

A.1.1 Calibration Unit 2

A.2 Plot Sheet RB211-524 3

A.2 Plot Sheet RB211-535 4

A.2.1 Scan Plan IPT Disc RB211-535 5

A.2.2 Scan Plan IPT Disc RB211-524 6

A.3.1 Dependency measurement-signal of inner width between part surface to fluxgate

- gradiometer bottom edge of a 10 mg defect 7

A.3.2 Distance determination of a defect to fluxgate gradiometer bottom edge 8

A.3.3 SQUID Evaluation Sheet 9**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 3 Oct. 8/10 Oct.12/12 R1. Scope and Purpose This specification covers SQUID inspection for the detection of ferromagnetic inclusions in RB211 IP Turbine discs.
2. Reference Documents For dated references subsequent amendments, or revisions of any of these publications, apply to this specification only when incorporated in it by amendment or revision. For undated references, the latest edition of the publication is applicable.
3. Definitions and Abbreviations
3.1 - Definitions RRD - Rolls-Royce Deutschland Ltd. and Co KG The word SQUID defines the measurement with fluxgate gradiometer and the electronics of the gradiometer.
Abbreviations GM02 - Basic Magnetic Measuring System CB01 - Calibration Ring working standard
DT01 - Turntable MH02 - Magnetising System DM01 - Demagnetiser ME01 - Electronic measuring equipment
AN01 - Drive Unit
DS01 - Distance Piece
DH01 - Distance Bush 4. Responsibilities In accordance to Quality Agreement No.
01041327 4.1 - Qualification and approval of SQUID - Inspection personnel**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 4 Oct. 8/10 Oct.12/12 RPersonnel for the SQUID - Inspection should be qualified and approved to the requirements of the NDE Training Pack TP0044.
5. Test Procedure 5.1 - Handling of turbine discs The handling should be restricted to the minimum requirements.
The turbine discs must be handled with maximum care. At all times the handling of turbine discs must be undertaken by two persons. Clean cotton gloves must be worn when handling the turbine discs.
Turbine discs should not be slid over surfaces. Incoming turbine discs must be stored in a dry closed room. Only one single turbine disc box may be open at a time. Turbine disc box should only be opened immediately prior to SQUID inspection process. No foreign material may contact the turbine discs. In the case of disc damage or any peculiarity, it must be reported to RRD ET-M in writing. Damage - any surface imperfection (dent, scratch, score) that is clearly visible with the naked eye under good lighting conditions. Peculiarity - visible indication of some foreign matter in contact with the surface of the component, e.g. liquid or solid, or any apparent discolouration that is not consistent with general visible appearance of the component. 5.2 - Test Equipment 5.2.1 - SQUID measuring system GM02
5.2.1.1 - Gradiometer (MAG-03IEL100) 5.2.1.2 - Electronics of gradiometer
(MAG-03PSU) 5.2.1.3 - Electronics measuring equipment (ME01) codec:

- Adaption electronics AE01 - Preamplifier (VV01) with voltage gain of 1000**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 5 Oct. 8/10 Oct.12/12 R- Low-pass filter (TP01) with cut -off frequency of 10 Hz 5.2.1.4 - Digital oscillioscope Vellemann

- PCSU 1000 Channel 1 (measurement signal) Input signal: DC Sensitivity: variable
Time-base 1s/div Channel 2 (trigger signal at 360 deg.) Input signal: DC Sensitivity: 100 mV/div 5.2.1.5 - Laptop with software PCSU 1000 and printer 5.2.1.6 - Calibration ring working standard (CB01) for inline system set up 5.2.1.7 - Turntable DT01, made of thermo plastic 5.2.1.8 - SQUID handling unit 5.2.2 - Magnetising system (550 Gauss) MH02 5.2.3 - Demagnetiser DM01 5.2.4 - Direct current motor with toothed belt (AN01), (3m distance to turntable) 5.2.5 - Distance piece DS01 (50x23x3 mm) 5.2.6 - Distance Bush DH01 (inner diameter 20,00 and height 50 mm) Gauge RB211-524/2 Gauge RB211-535/1 Gauge RB211-535/2
5.3 - Calibration Reference Cubic block of 1.6604 ( MSRR6017) material with 10 mg mass, magnetised to 550 Gauss (0,055T). The sample is glued in the thermoplastic calibration ring (CB01) see Appendix A1.1.**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 6 Oct. 8/10 Oct.12/12 R5.4 - Calibration Procedure The calibration procedure is to be carried out before and after each test session and shall be documented. If the inspection will be stopped for longer than two hours, a new calibration should be done. Check the equipment in accordance to internal procedure FITM 1 at the beginning of the inspection. 5.4.1 - Demagnetise the calibration sample with demagnetiser (DM01). Fix the calibration ring in the magnet with the 20 mm bore and the distance bush (DH01) of 50 mm height onto the bearing pin of the magnetising system (MH02). The calibration sample (red point) should be above. The permanent magnet shall be navigated to adjustment hole 18. R Turn the turntable 4 revolutions by hand, each round should require approx. 3 seconds. The calibration sample is magnetised R now and take the calibration block to the turntable (DT01). 5.4.2 - Centralise calibration ring (CB01) on the turntable 50 plus or minus 1 mm below GM02. Switch on the motor. The disk will rotate at approx. 20 RPM. Rotate minimum two revolutions, then store the data on the oscilloscope.
Switch off the motor. The calibration is valid, if the SQUID signal is 140mV plus or minus 7mV.
5.5 - Turbine Disc Test Procedure 5.5.1 - Calibrate the whole equipment in accordance to chapter 5.4. 5.5.2 - Mount the turbine disc on the turntable of the magnetiser (MH02) with the flange upward. Magnetise R the disc with permanent magnet (550 Gauss) in 30 mm steps from R R the middle completely. Turn the turbine disc 4 revolutions by hand for each position. Each revolution should be about 3 seconds. Magnetise the disc per position as described above. The turbine disc is magnetised now. 5.5.3 - Remove the permanent magnet and put the turbine disc with the flange downward on the turntable (DT01). The firtree No. 1 has to be positioned on the trigger signal. 5.5.4 - Regarding the radius, the gradiometer has to be positioned with aid of the gauges in accordance to scan plan appendix A2.1/2.2 (3mm above the surface)**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 7 Oct. 8/10 Oct.12/12 R5.5.5 - Switch on the motor. The disc will rotate clockwise respectively anti-clockwise at approx. 0,3 Hz. in accordance to the scan plan. 5.5.6 - When two consecutive revolutions give the same SQUID signal, store the scan, switch off the motor and plot the scan, see Appendix A1.2. 5.5.7 - If the defect signal is greater R than 80mV a second scan 20 mm above is required (3mm + 20 mm above the surface) - procedure in accordance to chapter 5.5.4 to 5.5.6. 5.5.8 - The procedure in accordance with chapter 5.5.4 to 5.5.7 must be repeated for each scan (see Appendix A2.1/A2.2). 5.5.9 - The disc will be turned, so that the flange side is upwards. The firtree no.1 has to be positioned on the trigger signal. Application flow in accordance to 5.5.4 to 5.5.8 for each receivable scan (see appendix A2.1/A2.2)
5.6 - Evaluation Procedure 5.6.1 - The defect signal of each scan must be determined and written in the table (see Appendix A3.3). 5.6.2 - Depending on the defect signal heights (see chapter 5.5.7), a +20 mm scan, may be necessary. 5.6.3 - Determine the ratio of Signal: signal +20 mm and enter in the column signal ratio. Determine in diagram (see Appendix A 3.2) the corresponding distance and enter in column distance. For defect size determination enter values of signal and distance out of evaluation sheet A3.3 in diagram (see Appendix A3.1). If the coordinates are above the 10mg-3sigma line the turbine disc is rejected, below the line the turbine disc is passed.**Printed in Great Britain**



# RB.211−72−AG493 Appendix 4 - Page 8 Oct. 8/10 Oct.12/12 RIllustrations and Tables APPENDIX A**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 1 of 9 Oct. 8/10 Oct.12/12 RA1.1 - Calibration Ring (CB01)**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 2 Oct. 8/10 Oct.12/12 RA1.2 - Plot Sheet RB211-524G/H & RB211-524G/H-T**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 3 Oct. 8/10 Oct.12/12 RA1.2 - Plot Sheet RB211-535E4**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 4 Oct. 8/10 Oct.12/12 RR

A2.1 - Scan - Plan RB211-535E4 R**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 5 Oct. 8/10 Oct.12/12 RR

A2.2 - Scan - Plan RB211-524G/H (&-T) R**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 6 Oct. 8/10 Oct.12/12 RA3.1 - Dependency measurement signal of inner width between part surface to fluxgate - gradiometer bottom edge for 10 mg defect**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 7 Oct. 8/10 Oct.12/12 RA3.2 - Distance determination of a defect to fluxgate gradiometer bottom edge**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 8 Oct. 8/10 Oct.12/12 RA3.3

SQUID Evaluation Sheet Facility: FITM Magdeburg Datum: Inspector: Signature: Trigger Signal: Firtree No 1RB211-524G/H; 524G/H-T RB211-535E4 Turn: Scan 1-9=anticlockwise
Turn: Scan 1-8=anticlockwise Scan 10-14=clockwise
Scan 10-12=clockwise
Part No: Part Description: IP turbine disc
S/N No.: Reference Document: QCTP BRR 0144 R R RB211 72-AG493 R Magnetic Status of Test Piece: Magnetised with 0,0550 T (550 Gauss)
Calibration carried out before test session:
Calibration carried out after test session: Signal (mV)Signal (mV) Scan X + 20 mm Signal ratioDistance (mm) Comments

Scan 1: Scan 2: Scan 3: Scan 4: Scan 5: Scan 6: Scan 7: Scan 8: Scan 9: Scan 10: Scan 11: Scan 12: Scan 13: Scan 14:
Test Result: Authorised Signature:
Date:**Printed in Great Britain**



# RB.211−72−AG493 Appendix A - Page 9 Oct. 8/10 Oct.12/12 RPictures of acceptable and unacceptable process cleaned discs R APPENDIX 5**Printed in Great Britain**



# RB.211−72−AG493 Appendix 5 - Page 1 of 6 Oct. 8/10 Oct.12/12 RR

Example of the general surface finish of an acceptable disc after process cleaning R Fig.1 R**Printed in Great Britain**



# RB.211−72−AG493 Appendix 5 - Page 2 Oct. 8/10 Oct.12/12 R Surface finish appears shiny. No oxide, corrosion or other contamination evidentR

Example of an acceptable disc firtree process cleaning R Fig.2 R**Printed in Great Britain**



# RB.211−72−AG493 Appendix 5 - Page 3 Oct. 8/10 Oct.12/12 R No other oxide, corrosion or other contamination present Very minor oxide deposits are acceptable in firtree serrationsR

Example of the general surface finish of an unacceptable disc after process cleaning R Fig.3 R**Printed in Great Britain**



# RB.211−72−AG493 Appendix 5 - Page 4 Oct. 8/10 Oct.12/12 R Surface finish dull - oxide layer still present. Other visible contamination evident. Disc not protected in transportation box (to keep clean)R

Example of an unacceptable disc firtree serration and rim after process cleaning R Fig.4 R**Printed in Great Britain**



# RB.211−72−AG493 Appendix 5 - Page 5 Oct. 8/10 Oct.12/12 R Excessive oxide scale still present in and around firtree serrations, disc post and disc rimR

Example of an unacceptable flange bolt and cooling air hole after process cleaning R Fig.5 R**Printed in Great Britain**



# RB.211−72−AG493 Appendix 5 - Page 6 Oct. 8/10 Oct.12/12 R Excessive oxide scale still present in disc bolt/cooling hole bore